Dual damascene technique has been widely applied to IC device fabrication in copper interconnect
process. For traditional via-first dual damascene application, a fill material is first employed to fill via to protect
over-etching and punch-through of the bottom barrier layer during the trench-etch process. Etch-back process is then
applied to remove excess overfill thickness and maintain a greater planar topography. To get better CD control, a thin
organic BARC is finally coated to reduce reflectivity for trench patterning but not in this study. It is a multi-step and
costly dual damascene process. In this study, a new gap-filling BARC material with good via fill and light
absorption features was adopted to explore the via-first dual damascene process by skipping etch-back and BARC
coating steps. The results show not only the reduction of process cycle time and cost saving but also the CP yield
improvement based on data from pilot production of 0.11/0.13 μm logic device.
So far the IC industry is using dyed resist and TARC for the implant layer lithography. However, this approach cannot provide the necessary CD control for the 65nm node and below. One could use organic BARC to improve CD control but the dry etching process can cause substrate damage and also add considerable expense to the process. Cox et al at Brewer Science have reported some wet developable BARCs with TMAH soluble polymers. However the development is isotropic for these materials and it is difficult to control the development process for profile shape and across wafer uniformity. In this paper we describe new developable KrF and ArF photosensitive developable BARCs (DBARCs) that use the concepts of positive chemical amplified resist concept. These DBARCs have significant advantages over the conventional BARCs and also over processes using TARC. These new DBARC provide a large pattern collapse margin and a good process window.
We will report in this study on the process evaluation of the combination of Clariant KrF and ArF resists and DBARCs. As the DBARC itself is also photosensitive the matching of the sensitivity with resist is important. The KrF DBARC and resist combination gives 180nm lines and spaces with a good process window. This meets the requirements of 65nm implant processes.
The IC industry is moving toward 90nm node and below. The CD size of implant layers has shrunk to 220nm. To achieve better CD uniformity, dyed KrF resist and top anti-reflective coating (TARC) are commonly used in advanced photo process of implant layers. It’s well known that bottom anti-reflective coating (BARC) has better reflection control over TARC. However, dry etching process is required if typical organic BARC is applied to photo process of implant layers. It is undesirable for two reasons. The first reason is the substrate damage caused by plasma etching could affect the device performance. The second reason is higher cost due to additional processing steps. In order to overcome those two shortcomings, developable BARC (DBARC) is introduced. It is a new type of BARC, which is soluble to developer, TMAH solution, in the resist development step. There are some reports on the developer-soluble KrF BARC. Most of them are polyamic acid and their solubility to alkline could be adjusted by changing bake condition. However, its development is isotropic, which make it difficult to get a vertical profile. Therefore, we have developed a photosensitive developer-soluble BARC (DBARC) which is anisotropic after exposure and thus results in a nice vertical profile. The photosensitive DBARC utilizes the same concept as chemically amplified resist. It has acid-cleavable groups in the resin and PAGs in the formulation. The photosensitive DBARC turns soluble to TMAH developer after exposure and resist PEB. The solubility difference caused by exposure makes developing process anisotropic and thus improves profile control. In this article, we will report the evaluation results of various combinations of KrF resists and DBARC for implant layers. Since both the resist and DBARC are photosensitive, matching of the photo speeds of them is essential. The amount and type of PAG in both the resist and the DBARC play a very import role. Finally, the optimized combination showed acceptable lithography process window and good CD uniformity over topography.
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